Polymers of methyl ethenyl benzene

ABSTRACT

A mixture of isomeric methyl ethenyl benzenes having a particular distribution of isomers is useful for preparing polymers with advantageous properties. The isomeric mixture may be polymerized with other monomers to produce copolymers.

CROSS REFERENCE TO RELATED APPLICATION

Application Ser. No. 706,981, filed July 19, 1976 (now U.S. Pat. No. 4,086,287) and Application Ser. No. 801,177, filed May 27, 1977, now abandoned in favor of Application Ser. No. 925,585, filed July 17, 1978, issued as U.S. Pat. No. 4,143,084.

POLYMERIZABLE MONOMER MIXTURE

This invention relates to a polymerizable mixture of isomeric methylstyrenes and to polymers of such mixtures.

THE PRIOR ART

Styrene has been used for a long period of time in the manufacture of polymers and polystyrene has attained a large market for many purposes. Alkylated styrenes such as alpha-methylstyrene have also been of interest for certain purposes.

The nuclear alkyl substituted styrenes have also been used in various applications. The monomer which has been principally used is known as vinyltoluene. This is a mixture which consists mainly of meta- and para-methyl styrenes (vinyl toluenes) produced by the catalytic dehydrogenation of a mixture of the corresponding m- and p-ethyltoluenes. The ethyltoluene mixture is itself obtained by the fractional distillation of a mixture of the o-, m- and p-ethyltoluenes. The ratio of the m- and p-isomers in the monomer mixture is approximately 65:35 (m:p). A convenient summary of the preparation and properties of the monomer mixture and of polymers produced from it is given in "Styrene: Its Polymers, Copolymers and Derivatives" Ed. R. H. Boundy, R. F. Boyer, ACS Monograph Series, 1952, Hafner Publishing Company, pages 1232 to 1245.

THE INVENTION

We have now found that polymers with advantageous properties can be prepared from a mixture of isomeric methyl ethenylbenzenes having a particular isomeric distribution.

The polymerizable isomeric mixture consists essentially of the m- and p-isomers of methyl ethenyl benzene. The mixture is substantially devoid of the o- isomer; when the o-isomer is present, the amount of it is less than 0.1% based on the total weight of the isomer mixture.

The ratio of the isomers in the mixture is as follows:

    ______________________________________                                         Isomer             Wt. Percent                                                 ______________________________________                                         1-methyl-2-ethenyl benzene                                                                        Less than 0.1, preferably                                                      less than 0.05.                                             1-methyl-3-ethenyl benzene                                                                        Less than 15, preferably                                                       less than 10.                                               1-methyl-4-ethenyl benzene                                                                        85-99 preferably at least 90.                               ______________________________________                                    

Generally, the proportion of the p-isomer (1-methyl-4-ethenyl benzene) will be at least 95 weight percent with the m-isomer (1-methyl-3-ethenyl benzene) constituting less than 5 weight percent of the mixture. Particularly preferred mixtures contain 97 to 99 weight percent of the p-isomer and 1 to 3 weight percent of the m-isomer.

The isomer mixture may contain impurities and adventitious materials in addition to the methyl ethenyl benzenes. Generally, these other materials will not constitute more than 1 percent by weight of the total mixture. These other materials derive essentially from the process used to make the methyl ethenyl benzenes.

A typical isomer mixture has the following analysis, by weight, determined by gas chromatography:

    ______________________________________                                                                Wt. percent                                             ______________________________________                                         Total vinyl benzenes         99.41                                             Residue:                                                                       Ethyl toluene       0.10                                                       Mesitylenes etc.    0.15                                                       Non-vinylic                                                                    higher boilers      0.34                                                                           0.59     0.59                                                                           100.00                                            Vinyl benzenes:                                                                1-methyl-2-ethenyl benzene   0.05                                              1-methyl-3-ethenyl benzene   2.6                                               1-methyl-4-ethenyl benzene   97.4                                              ______________________________________                                    

The mixture of the isomeric methyl ethenyl benzenes may be obtained by the catalytic dehydrogenation of a mixture of the corresponding ethyl toluenes, which in turn may be obtained by the selective alkylation process disclosed and claimed in co-pending United States Patent Application Ser. No. 706,981, filed July 19, 1976 (now U.S. Pat. No. 4,086,287) and Ser. No. 801,177 (now abandoned in favor of Application Ser. No. 925,585, filed July 17, 1978, issued as U.S. Pat. No. 4,143,084), filed May 27, 1977 by Warren W. Kaeding and Lewis B. Young, the disclosures of which are incorporated herein by reference.

In its application to the production of the methyl ethenyl benzenes, the method disclosed in the Kaeding et al applications essentially involves the alkylation of toluene with ethylene in the presence of certain crystalline aluminosilicate zeolite catalysts. The catalyst has a silica to alumina ratio of at least 12 and a constraint index (defined in the application) within the range of 1 to 12. The process produces an extremely high proportion of the 1-methyl-4-ethyl benzene isomer, with only a minor proportion of the 1-methyl-3-ethyl benzene isomer and negligible amounts of the 1-methyl-2-ethyl benzene isomer. The almost complete absence of the 1-methyl-2-ethyl isomer is highly advantageous because this isomer tends to produce undesired by-products during the dehydrogenation step (indanes and indenes which adversely affect the properties of the resultant polymers and which cannot be easily separated from the methyl ethenyl benzenes).

The mixture of isomeric methyl ethyl benzenes may be subjected to distillation prior to the hydrogenation step in order to separate out various by-products and after the hydrogenation has been completed, a further distillation may be carried out to separate the methyl ethenyl benzenes from their saturated precursors.

Since the proportion of the 1-methyl-4-ethenyl benzene in the mixture is so high, usually at least 95 by weight, the mixture can be regarded essentially as the para (1,4-) isomer. For convenience in this specification, therefore, the mixture may be referred to as "the para monomer" and the polymer produced by the polymerization of this mixture in the absence of other monomers as "the homopolymer" in order to distinguish it from polymers produced by polymerizing the mixture with other, copolymerizable monomers. It should, however, be remembered that "the homopolymer" is, in fact, a copolymer of the isomeric monomers.

The mixture of the isomers may be polymerized by itself to produce "the homopolymer" or with other copolymerizable monomers to produce copolymers. In general, the polymerization conditions appropriate to styrene will also be useful with the methyl ethenyl benzene mixture, whether polymerized by itself or with other monomers. Thus, polymerization may be effected under bulk conditions or in solution, suspension or emulsion techniques comparable to those used for styrene polymerization. The polymerization catalysts may be of the free radical, anionic or cationic types. Suitable free radical initiators include di-tertiary butyl peroxide, azobis (isobutyronitrile), di-benzoyl peroxide, tertiary butyl perbenzoate, di-cumyl peroxide and potassium persulfate. Cationic initiators are generally of the Lewis acid type, for example, aluminum trichloride, boron trifluoride, boron trifluoride etherate complexes, titanium tetrachloride and the like. Anionic initiators are generally of the formula RMy where R is organo, mono- or polyvalent and may be alkyl, alkenyl, aryl, aralkyl, and alkaryl, and may contain from 1 to about 50 carbon atoms; and y is 1 to 4, and preferably 1 or 2. Such initiators as methyl lithium, ethyl lithium, methyl sodium, propyl lithium, n-butyl lithium, sec-butyl lithium, tert-butyl lithium, butyl sodium, lithium naphthalene, sodium naphthalene, potassium naphthalene, cesium naphthalene, phenyl sodium, phenyl lithium, benzyl lithium, cumyl sodium, cumyl potassium, methyl potassium, ethyl potassium, and so forth may be used in this reaction. Also, metal initiators containing a dianion, such as the alkali metal salts of 1,1-diphenylethylene and alpha-methylstyrene tetramer and the radical anion initiators of the sodium naphthalene type may be used. Branched chain polymers may be obtained by using multifunctional initiators, for example 1,3,5-trilithiocyclohexane and 1,4,7,10-tetrapotassiodecane. In the anionic polymerization each molecule of the initiator starts one anionic polymer chain; multiple anions can permit addition of secondary chains to the main chain. Stereospecific catalysts can also be used to advantage. Such catalysts are generally of the well known Ziegler type, comprising a transition metal of Group 4A, 5A, 6A or 7, a valence state lower than its maximum in combination with an organometallic compound of Group 2 or 3.

Among the reducible transitional metal compounds suitable for the purposes of this invention are the heavy metal, inorganic compounds such as halide, oxyhalides, complex halides, hydroxides, and organic compounds such as alcoholates, acetates, benzoates, and acetyl acetonates, of the requisite metals. Such metals include titanium, zirconium, hafnium, thorium, uranium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten and iron. The metal halides, particularly the chlorides are generally preferred. Titanium, zirconium, and vanadium are the most active metals. The following heavy metal compounds are readily reducible: titanium tetrachloride, titanium tetrabromide, zirconium tetrachloride, vanadium tetrachloride, and zirconium acetylacetonate.

The reduction may be effected in any suitable manner, for example, by reduction with hydrogen or aluminum. Titanium tetrachloride can be readily reduced to titanium trichloride by reduction with hydrogen, aluminum or titanium metal. Suitable reduction methods are well known in the art and are described, for example, in U.S. Pat. No. 3,362,940.

The other component of the catalyst system is at least one organometallic compound of a metal of Groups 2 or 3. These compounds will have at least one hydrocarbon radical, i.e., alkyl, cycloalky, aralkyl, alkaryl, or aryl, attached to the metal through a carbon atom. The other substituents in the organometallic compound can be hydrocarbon radicals, halogen radicals, alkoxy, amino, hydrogen, etc., or combinations thereof. Non-limiting examples of the organometallic compounds are triethylaluminum, tripropylaluminum, dipropylzinc, triisobutylaluminum, diethylmagnesium, diphenylaluminum chloride, cyclohexyl-ethylzinc, diethylaluminum bromide, diethylaluminum chloride, diethylaluminum iodide, ethyl-zinc chloride, propylmagnesium chloride, dipropylaluminum chloride, dioctylaluminum chloride, diisobutylaluminum hydride, phenylaluminum dihydride, cyclohexylbromoaluminum hydride, dipropylaluminum hydride, propyl zinc hydride, ethylmagnesium hydride, and methoxyaluminum diethyl. Mixtures of two or more organometallic compounds can be used.

The catalyst can be formed by methods well known in the art. Thus, for example, it can be made by charging the components separately to the polymerization zone or they may be combined immediately prior to entry into the zone.

As previously mentioned, the polymerization may be carried out in bulk, in solution, in suspension or in emulsion. Solution polymerization will generally employ inert hydrocarbon solvents such as toluene, benzene or ethyl toluene. Suspension polymerization is generally carried out in an aqueous medium comprising water and suspending agents such as calcium phosphates, polyvinyl alcohol, hydroxyethyl cellulose or sodium polyacrylates. Suitable suspension polymerization techniques will be comparable to those used with styrene monomer, which are well known in the art and described, for example, in U.S. Pat. No. 2,715,118. Emulsion techniques also will be comparable to those used for styrene, using an aqueous medium with the addition of suitable surfactants. Catalysts will normally be of the free-radical type, for example, a combination of butyl peroxide and tertiary butyl perbenzoate.

Polymerization may also be carried out thermally.

The polymerization conditions will generally be similar to those used for styrene. Thus temperatures will generally be in the range of 0° to 200° C., preferably 50° to 150° C., with a range of about -80° C. to +30° C. being most appropriate for cationic polymerization.

The polymers produced by polymerizing the mixture by itself have unexpected and advantageous properties. They have a higher glass transition temperature than polystyrene (which means that the polymer retains its solid state properties at high temperatures), a higher Vicat softening point than polystyrene and a lower density than polystyrene. They are also cross-linkable either by radiation e.g. electron beam irradiation or gamma ray, or by chemical cross-linking agents such as dicumyl peroxide and other peroxidic compounds (this is in surprising contrast to the behavior of polymers of styrene which depolymerize when attempts are made to cross-link them chemically with peroxides: the polymers of the present invention cross-link to give insoluble, infusible products). Although the polymers of the present invention have a greater affinity for hydrocarbon solvents than polystyrene (as evidenced by a higher pentane absorption) this can be reduced by polymerizing the mixture with a barrier type monomer such as acrylonitrile. The greater affinity for hydrocarbons is, however, advantageous in the production of expendable beads (for example, similar to those described in British Patent No. 1049144) because the hydrocarbon blowing agents will be retained to a greater degree by the polymer.

The homopolymers can be readily sulfonated and subjected to other electrophilic substitution reactions such as chlorination and bromination. These reactions occur more readily than with polystyrene. The sulfonation can be continued to a degree such that the resultant sulfonated material is water soluble. Control of the degree of sulfonation can therefore be used to regulate the solubility characteristics of the material. The sulfonate groups may, of course, be neutralized by alkalies such as ammonia, sodium hydroxide, potassium hydroxide and the like to give a neutral material. Sulfonating agents such as sulphonyl chloride, chlorosulfonic acid and sulfur trioxide or sulfuric acid (oleum) may be used to effect the sulfonation. Nuclear halogenation may be carried out by contact with the appropriate halogen, preferably (but not necessarily) in the presence of a suitable catalyst such as a Lewis acid for example, ferric chloride or ferric bromide. The halogenated polymers, especially the brominated ones, are non-flammable and self-extinguishing materials. Halogenation of the methyl side chains can be carried out by the use of a halogenating agent under free-radical conditions, for example, in the presence of a peroxide or under light or ultra-violet radiation. Organometallic groups can be inserted by reaction of organometallic halides such as tin trimethyl chloride, boron dimethyl chloride or lead trimethyl chloride in the presence of a Friedel-Crafts catalyst. The resulting materials may form catalysts or radiation resistant polymers.

The polymers are also notable in that faster cycle times are possible for injection molding than with polystyrene and a greater degree of thermal stability is indicated.

The higher glass transition temperature T_(G) of the polymers, as compared to polystyrene, is a significant advantage. In general, polystyrene has a glass transition temperature of 100°-103° C. as measured by Differential Scanning Calorimeter (DSC) by the method described below. The polymers of the present invention, however, generally have a glass transition temperature above 105° C., usually above 110° C. The exact temperature has been found to depend upon the content of the p-isomer in the monomer mixture, increasing with increasing p-isomer content, as shown in Table 1 below:

                  TABLE 1                                                          ______________________________________                                         Content of                                                                     1-methyl-4-          T.sub.G                                                   ethenyl benzene,     (by DSC)                                                  wt. percent          °C., ± 1° C.                             ______________________________________                                         99.7                 113                                                       97.0                 111                                                       95.5                 110                                                       89.3                 106                                                       76.2                 100                                                       ______________________________________                                    

By comparison, the polymer of "vinyl toluene" (which contains about 34% of the p-isomer) is only about 88° C.

The DSC method used to determine the glass transition temperature is as follows:

Sample Preparation: A 500 m.g. sample is weighed in tared pan and transferred to 11/4" diameter mold in a Buehler Press and heated to approximately 190° C. The heat is removed and pressure applied to form a disk in the cavity and the disk is cooled. A sample specimen is punched from disk with a No. 7 belt punch and encapsulated in standard sample pan. The sample will weigh 15 to 20 mg.

Analysis: The encapsulated sample is placed in the Differential Scanning Calorimeter Sample Holder. Nitrogen is supplied to the calorimeter at 20 p.s.i. gauge to maintain an inert atmosphere around the sample during the test. The sample is heated at 20° C./min. to a temperature 20° C. above the glass transition temperature. Cooling at 20° C./min, is then permitted to a temperature approximately 80° C. below the observed glass transition. After the sample has equilibrated for 2 min., it is heated at 20° C./min. and the thermogram recorded. Convenient recorder settings are 40 mm./min. chart speed (corresponding to 12.7° C./min) with full scale deflection of 1 millicalorie/second.

The glass transition is the intersection of the baseline and the sloping change in heat capacity of the sample as the temperature increases.

The polymers are also notable for a higher Vicat softening temperature than polystyrene. Vicat softening temperature is measured by ASTM method D-1525. It, also, has been found to vary with the content of p-isomer in the monomer mixture, as shown below in Table 2:

                  TABLE 2                                                          ______________________________________                                         Content of                                                                     1-methyl-4-ethenyl    Vicat                                                    benzene, wt. percent  °C. ± 1° C.                             ______________________________________                                         99.7                  118                                                      97.0                  119                                                      95.5                  114                                                      89.3                  108                                                      ______________________________________                                    

By comparison, styrene has a Vicat of about 107° to 108° C. and the polymer of "vinyl toluene" a Vicat of only 97° C. Thus, the present homopolymers are characterized by a Vicat temperature of at least 108° C., generally at least 110° or 112° C.

The polymers will generally have a molecular weight corresponding to intrinsic viscosities of 0.1 to 10 (toluene/30° C.). This will generally correspond to molecular weights of at least 30,000, with most molecular weights (Mv-viscosity average) being about 250,000 to 275,000 for commercial materials. The glass transition temperatures for very low molecular weight materials (below 50,000) may be lower than those indicated and therefore not suited for uses where solid state properties are desired. The melt indices will normally be in the range 2.0 to 3.0, generally 2.0 to 2.5. Good optical properties as indicated by transmittances of at least 88% are typical of the polymers. The pentane uptake is generally about 40%, as compared to about 1-2% for polystyrene, thereby indicating a greater affinity for hydrocarbons.

The polymerizable mixture may also be copolymerized with other monomers. The conditions for the copolymerization will, in general, be similar to those used for polymerizing the mixture by itself and for copolymerizing styrene. Thus, initiators, temperatures, pressures, solvents and recovery processes will be similar to those previously described. The types of copolymer produced may include random, regular, block and graft copolymers. The preparative procedures will be those appropriate to the type of copolymer in question.

Random copolymers may be made with a wide range of comonomers including other vinyl monomers such as styrene, alpha-methyl styrene, acrylates including methyl acrylate, ethyl acrylate, methacrylates including methyl methacrylate, acrylonitrile, olefins especially diolefins such as butadiene, isoprene, chloroprene and mono olefins such as ethylene and propylene.

A particularly preferred class of random copolymers are the random copolymers with butadiene. They may be produced by methods similar to those used in the manufacture of GR-S synthetic rubber and described, for example, in "Synthetic Rubber", Ed. Whitby et al. John Wiley, New York, 1954. A suitable polymerization mixture is shown in Table 3 below:

                  TABLE 3                                                          ______________________________________                                         Butadiene - MEB Polymerization                                                 Formula                                                                                          Parts per 100 parts                                                            Total Monomers                                               ______________________________________                                         Butadiene           70                                                         Methyl-ethenyl benzene                                                          mixture            30                                                         Dodecyl mercaptan   0.5                                                        Potassium persulfate                                                                               0.23                                                       Soap (anhydrous basis)                                                                             4.3                                                        Water               180                                                                            285.03                                                     ______________________________________                                    

Generally, a slightly greater proportion by weight will be required for the methyl ethenyl benzene mixture, as compared to styrene, because of its higher molecular weight. However, the polymerization conditions used for styrene will be generally applicable with the new monomer mixture.

The copolymers with styrene exhibit minimal haze and loss of transmittance for all relative proportions of the comonomers. Although most physical properties are intermediate to those of polystyrene and the homopolymer, a minimum in the glass transition temperature occurs at about 70% styrene in the copolymer. Also, there is a minimum in the pentane uptake (i.e. minimal affinity for hydrocarbons) at about 65% styrene in the copolymer. The pentane uptake increases rapidly from 50 to 65% styrene.

The copolymers with acrylonitrile are a specially preferred class of copolymers. They have a low affinity for hydrocarbons, especially as compared to the homopolymer. The affinity for hydrocarbons can therefore be controlled by copolymerizing the monomer mixture with varying amounts of acrylonitrile. Generally, the amount of acrylonitrile will be from 15 to 35%, preferably about 30%, by weight, although lower amounts from 5 to 15% e.g. about 10% of the comonomer will effect useful changes in the properties of the polymer, as shown in Example 8 below.

Another favored class of copolymers are the high impact copolymers. These are generally graft copolymers produced by grafting units derived from the polymerizable mixture onto a backbone polymer which is generally of a rubbery nature. Suitable backbone polymers include polybutadiene, poly(dimethyl butadiene), polyisoprene, polychloroprene and other synthetic rubbers such as the styrene-butadiene rubbers (SBR) ethylene-propylene rubbers (EPR), ethylene-propylene-diene elastomers, polyacrylates, nitrile rubbers and copolymers with other aromatic monomers including vinyl toluene. The backbone will generally comprise 2 to 25 percent by weight of the high impact copolymer, preferably 3 to 10 percent by weight. Normal techniques, e.g. grafting, comparable to those used for making high impact polystyrenes are useful; they are well known in the art and referred to, for example, in U.S. Pat. No. 2,694,692 and British Pat. No. 1054301.

The high impact copolymers derived from ethylene-propylene-diene elastomers are particularly advantageous in their high temperature stability and weatherability. The copolymers produced from polyisoprene have exceptionally high impact strengths as shown by their Izod impacts. Furthermore, the high impact copolymers according to the present invention are more translucent in thin sections than similar high impact polystyrenes. This is probably because the refractive index of the present polymers is closer to that of the backbone polymers than that of polystyrene. A typical comparison of properties is given in Table 4 below. The samples were high impact materials containing 4.89 phm (parts per hundred monomer) of cis-polybutadiene.

                  TABLE 4                                                          ______________________________________                                         High Impact Materials                                                                                    Methyl                                                                         Ethenyl                                                               Styrene  Benzene                                              ______________________________________                                         Tensile Modulus, psi                                                                              24,000     255,000                                          Yield Strength, psi                                                                               3,500      --                                               Break Strength, psi                                                                               3,320       3,710                                           Elongation, %      14         7.1                                              Izod Impact (Ft-lbs/in)                                                                           1.3        2.10                                             Vicat Softening, °C.                                                                       100.5      108                                              % Transmission     77.0       83.8                                             Density            1.04       1.01                                             ______________________________________                                    

The monomer mixture is particularly suitable for use as a reactive diluent for thermosetting polyester resins. When mixed with polyesters the monomer mixture produces a resin mix of lower viscosity than vinyltoluene (when used at the same concentration). The cure reaction, on the other hand, is less exothermic than that of vinyl toluene being more comparable to that of styrene. At the same time, however, the mixture has a higher boiling point and lower vapor pressure than styrene. It therefore has the advantages both of styrene (slower polymerization rate, less exotherm) and of vinyl toluene (higher boiling point, lower vapor pressure).

The polyesters are generally of the liquid or semi-liquid molding, lay-up or spray-up types. Generally they will be solid or semi-solid materials which can be dissolved readily in the monomer mixture on heating. The polyesters will normally be derived from polyhydric alcohols such as ethylene glycol, propylene glycol, butane-1,4-diol or alkylene oxides such as ethylene oxide or propylene oxide. Since linear materials are desired, the alcohol will normally be dihydric. The acids used to make the polyesters are generally dicarboxylic acids such as maleic acid, iso-phthalic acid, terephthalic acid, and their anhydrides e.g. phthalic anhydride. Halogenated derivatives such as tetrabromo phthalic anhydride will yield self-extinguishing (non-flammable) materials. The relative amounts of the mixture and the polyester will normally be in the range of 10 to 50 percent mixture, preferably 30 to 40 of the mixture, by weight. Cure conditions and catalysts for the resin blends will be comparable to those for polyester/styrene blends. Thus, peroxide catalysts will normally be used, optionally with an amine or metallic ion co-catalyst such as N,N-dimethyl-aniline or cobalt octoate. Benzoyl peroxide is a convenient peroxy curing catalyst. Other suitable catalysts will be apparent to those skilled in the art.

The polyester blends will be useful for bulk molding, sheet molding, lay-up, spray up, filament winding and other techniques familiar to those in the art.

The mixture may also be polymerized with monomers such as ethylene oxide and ethylene sulfide to form polar copolymers. Block copolymers with ethylene oxide and sulfide containing from 1 to 50 percent by weight of the polar segment are highly useful as lubricating oil, thickeners, viscosity improvers and detergents. The preparation of these materials will follow the procedures disclosed in U.S. Pat. Nos. 3,867,295 and 3,954,915, except that the styrenic monomers referred to in that patent will be replaced by the monomer mixture according to the present invention. Thus, the monomer mixture will be co-polymerized with a diene such as butadiene or isoprene under anionic conditions using an anionic initiator such as butyl lithium or styrene sodium until the desired molecular weight for the oleophilic segment is reached, generally from 1000 to 250,000. This step of the polymerization is preferably carried out in the presence of a randomizing agent such as diethyl ether, dimethoxyethane or any of the other randomizing agents disclosed in U.S. Pat. Nos. 3,867,295 and 3,954,915, the disclosures of which are incorporated herein by reference.

The initial diene/methyl-ethenyl benzene copolymer is then hydrogenated to remove residual vinyl groups. The initial copolymerization may first be terminated by adding a small amount of the polar compound, such as ethylene oxide, followed by a small amount of a mineral acid or acetic acid and subjecting it to hydrogenation or by hydrogenating first and then acidifying. The hydrogenation may also be carried out following the complete addition of the polar block, such as that of ethylene oxide.

The hydrogenation and addition of the polar block is carried out as described in U.S. Pat. Nos. 3,867,295 and 3,954,915. Chain terminating (capping) agents of the type disclosed in these patents are also advantageously used in the same manner as disclosed in the patents e.g. isocyanates such as tolylene or phenylene diisocyanates and alkyl isocyanates.

The initial polymerization reaction may suitably be conducted at a temperature in the range of from -80° to 100° C., but ordinarily room temperature is the desired maximum. The reaction may be terminated within a period of from 15 minutes to over about 4 hours. The second reaction with alkylene oxide or sulfide may be conducted at a temperature of from 0° up to about 175° C., and the time of reaction may range from about half an hour to about 24 hours. The products can be recovered by filtering the precipitated copolymer from the solvent or as preferred by adding a hydrocarbon oil (in which the copolymer can be used) or a process oil and removing the more volatile solvent by stripping or other known means. Should a capping group other anh --OM (M is the metal of the initiator) be desired, the reactant providing the group is added to the reaction mixture prior to such separation and the mixture is heated. For example, the addition of toluene diisocyanate to the reaction product would yield a TDIK end group (wherein M is potassium). Any metal halide or oxide side product resulting from the capping reaction may be removed by washing and/or filtration. The retention of metals may be preferable as disclosed in the earlier patents. The block copolymers produced in this way will consist essentially of polymerized methyl ethenyl benzene type block having an average molecular weight of between 1,000 to about 300,000 and a polar portion, preferably polypoxyalkylene, having from 2 up to about 3,500 units, preferably 10 to 1,000 units. Preferred molecular weights of the copolymer will range from about 1,000 to about 300,000 and preferably from 10,000 to about 200,000.

Other viscosity index improvers can be made by copolymerizing the mixture according to the invention with comonomers such as tert.-butylstyrene, acrylates, methacrylates, and ethacrylates such as methyl methacrylate, ethyl methacrylate, ethyl acrylate and so forth. Significant improvements in viscosity index can be obtained without serious deterioration in pour point.

The following Examples are given in order that the invention may be more fully understood. Proportions and percentages are given by weight. The mixture of isomeric methyl ethenyl benzenes used in all the Examples was the same as that in Example 1 below.

EXAMPLE 1 Preparation of polymer from mixture of methyl-ethenyl benzene isomers

The mixture of methyl ethenyl benzene isomers used had the following composition (weight percent):

    ______________________________________                                         Methyl ethenyl benzenes   99.43                                                Ethyltoluene              0.53                                                 Xylenes, cumenes, mesitylenes                                                                            0.01                                                 High boiling materials    0.03                                                 Methyl ethenyl benzenes:                                                       1-methyl-2-ethenyl benzene                                                                               - (1)                                                1-methyl-3-ethenyl benzene                                                                               3.0                                                  1-methyl-4-ethenyl benzene                                                                               97.0                                                 ______________________________________                                          Note:-                                                                         Less than 0.05%.                                                         

The mixture (120 g.) was dissolved in 46.75 g toluene and 0.168 g. azobis (isobutyronitrile) and poured into a dry bottle which was then closed by a coupling/ball valve assembly. Dry nitrogen was then bubbled through the mixture in the bottle for 10 minutes by means of a needle inserted through the septum and the open ball valve. The nitrogen exited through a short needle piercing the septum on top of the ball valve. The two needles were then removed, the ball valve closed and the bottle placed in an oil bath at 60° C. for 96 hours and at 90° C. for 24 hours.

The polymerized mixture was removed from the bottle by dissolving it in additional toluene at 90° C. The volume of the final solution was about 400 ml. The polymer was then precipitated by pouring the solution into about 1000-1500 ml methanol in a 4 liter blender (Waring Blendor), adjusting the stirring speed to shred the polymer. The liquid was decanted and the polymer washed once with methanol in the blender. The solid polymer was filtered off and dried in a vacuum oven at 100° C. under vacuum for 48 hours.

The properties of the polymer were as follows:

    ______________________________________                                         Molecular wt (M.sub.v -13 viscos. Ave)                                                                 269 × 10.sup.-3                                  (M.sub.n -number Ave)   158 × 10.sup.-3                                  T.sub.G, °C.     111                                                    Vicat, °C.       119                                                    Deflection temp. °C.                                                                            98                                                     Melt Index (Cond G)     2.1                                                    Density g/cc            1.008                                                  Break strength, psi     6065                                                   Elongation, %           3                                                      Tensile Modulus:                                                               Rheovibron, psi × 10.sup.-3                                                                      331                                                    Instron, psi × 10.sup.-3                                                                         338                                                    Impact strength, ft/lb-in                                                                              0.20                                                   Haze                    4.4                                                    Transmittance, %        89.7                                                   Pentane uptake          41.0                                                   ______________________________________                                    

EXAMPLES 1A, 1B, 1C

Polymers prepared in the same way as in Example 1 from similar monomer mixtures containing different proportions of the p-isomer (1-methyl-4-ethenyl benzene) had the following properties:

    ______________________________________                                         Example           1A       1B       1C                                         ______________________________________                                         p-isomer content, %                                                                              89.3     95.5     99.7                                       Molecular wt (M.sub.v × 10.sup.-3)                                                         271      278      269                                        (M.sub.n × 10.sup.-3)                                                                      --       168      177                                        T.sub.G, °C.                                                                              106      110      113                                        Vicat, °C. 108      114      118                                        Deflection temp. °C.                                                                      93       108      104                                        Melt Index, (Cond G)                                                                             3.0      2.4      2.3                                        Density g/cc      1.014    1.011    1.008                                      Break strength, psi                                                                              6010     5330     5170                                       Elongation, %     1.4      8        3                                          Tensile Modulus                                                                Rheovibron, psi × 10.sup.-3                                                                363      325      355                                        Instron, psi × 10.sup.-3                                                                   309      301      332                                        Impact Strength, ft/lb-in                                                                        0.28     0.13     0.21                                       Haze              5.0      4.2      5.2                                        Transmittance, %  88.3     88.7     88.7                                       Pentane uptake    40.0     40.0     40.0                                       ______________________________________                                    

EXAMPLE 2 Preparation of a high impact material with an ethylene-propylene-diene elastomer (EPDM)

A quantity of 220 g the mixture of Example 1, 1.1 g mineral oil ("Nujol") and 11.0 g EPDM ("Royalene "515"-trade mark) (E DM) were added to a 1 liter reactor equipped with a stirrer and allowed to dissolve. A quantity of 0.071 g of azobisisobutyronitrile was added and the temperature raised to 90° C. and the stirring speed at 350 rpm. After heating for 2 hours at 90° C., 0.108 g of benzoyl peroxide was added and the stirring increased to 450 rpm. After 31/2 hours heating at 90° C., 0.07 ml t-dodecylmercaptan, 0.135 g t-butylperbenzoafte and 1.582 g t-butylperoctoate were added. After a few minutes mixing, an aqueous solution at 90° C., consisting of 320 ml distilled water, 0.59 g Gelvatol 20-90 (surfactant) and 1.35 g sodium chloride, was added and the stirring speed was increased to 550 rpm, the temperature was raised to 94° C. and held for 16 hr. The temperature was then raised to 96° C. and held for an additional 24 hours.

After the polymerization, the product was collected as small beads, dried and tested.

Test results were as follows: Izod Impact--1.14 ft-lb/in, Tensile Modulus--239, 000 psi, Break Strength--3970 psi, Melt Index--3.40 g /10 minutes. Vicat Softening temperature--104° C., Transmission --60.8%.

EXAMPLE 3 Preparation of a high impact copolymer with polyisoprene

A quantity of 220 g of the mixture of Example 1, 1.1 g mineral oil ("Nujol") and 11.0 g polyisoprene (Ameripol 600) were added to a 1 liter reactor equipped with stirring and allowed to dissolve. A quantity of 0.071 g of azobisisobutyronitrile was added and the temperature was raised to 90° C. and the reaction was stirred at 350 rpm. After 2 hours heating a 90° C., 0.108 g of benzoyl peroxide was added at 90° C. and the stirring increased to 450 rpm. After 3 hr 30 min at 90° C., 0.07 ml of t-dodecylmercaptan, 0.135 g t-butylperbenzoate and 1.582 g of t-butylperoctoate were added. After a few minutes mixing, an aqueous solution at 90° C. consisting of 320 ml distilled water, 0.59 (polyvinyl alcohol) (Gelvatol 20-90) and 1.35 sodium chloride was added to the prepolymer. The stirring speed was raised to 550 rpm, and the temperature increased to 94° C. and the reaction allowed to proceed overnight, the following day, the temperature was raised to 96° C. and allowed to proceed for an additional 24 hr.

After the polymerization, the product was collected as small beads, dried and tested.

The test results were as follows: Izod Impact--1.90 ft-lb/in, Tensile Modulus--241,000, Break Strength--3260, Vicat Softening 100° C., Melt Index--3.83 g /10 min. Transmission=81.7%.

EXAMPLE 4 Preparation of a high impact copolymer with nitrile rubber

A quantity of 200 g of the mixture of Example 1, 1.1 g ("Nujol"), and 11.0 g nitrile rubber ("Paracril 3300"-trade mark) was added to a 1-liter reactor equipped with stirring and allowed to dissolve. A quantity of 0.071 g of azo-bisisobutyronitrile was added and the temperature was raised to 90° C. and 350 rpm. After 2 hr heating at 90° C. and 350 rpm, 0.108 g of benzoyl peroxide was added and the reaction allowed to continue. After 3 hr 30 min at 90° C., 0.07 ml. of t-dodecylmercaptan, 0.135 gm. t-butylperbenzoate and 1.582 gm. t-butyl peroctoate were added. After a few minutes mixing, an aqueous solution at 90° C. consisting of 320 ml distilled water, 0.59 grams (polyvinylalcohol) (Gelvatol 20-90) and 1.35 g sodium chloride was added to the prepolymer and the stirring speed was increased to 550 rpm and the temperature increased to 94° C. The reaction was allowed to proceed for 16 hr at 94° C. and the temperature was raised to 96° C. for an additional 24 hr.

After the polymerization, the product was collected as small beads, dried and tested.

Test results were as follows: Izod Impact--0.79 ft-lb/in, Tensile Modulus--288,000, Break Strength--5220 psi, Melt Index=2.45 g/10 min Transmission=83.4%, Vicat and Softening Point--106° C.

EXAMPLE 5 Preparation of a high impact copolymer with polybutadiene

A quantity of 226 g of the mixture of Example 1, 1.1 g mineral oil ("Nujol") and 11.0 g of polybutadiene (Taktene 1202) were added to a 1 liter reactor and allowed to dissolve. A quantity of 0.071 g of azobisisobutyronitrile was added and the temperature raised to 90° C. Stirring speed was set at 300 rpm. After 2 hr at 90° C. and 300 rpm, 0.108 g of benzoyl peroxide was added and the reaction was continued at 90° C. and 300 rpm. After 4 hr 25 min after the start, 0.05 ml of t-dodecylmercaptan 0.150 g t-butylperoctoate, and 0.135 g of t-butylperbenzoate were added at 90° C., 300 rpm. After a few minutes of mixing, a water solution (320 ml) containing 0.59 g of polyvinyl alcohol (Gelvatol 20-390) and 1.35 g of sodium chloride was added at 90° C. to the polymer mix. The stirring speed was increased to 600 rpm and the temperature raised to 94° C. The suspended polymer was allowed to react for 16 additional hr at 94° C.

The final product was recovered in the form of small beads which were subsequently molded and tested.

The test results were as follows: Izod impact--2.10 ft-lb/in, Tensile Modules 255,000 psi, Break Strength--3710 psi, Melt Index--1.10 g/10 min, Vicat Softening Temp. -108° C., density=1.01 g/cc, and transmission=83.8%.

This copolymer is notable for its high softening temperature, low density and high transparency.

EXAMPLE 6 Preparation of a high impact copolymer from acrylonitrile/butadiene/methyl ethenyl benzene

Into a clean, dry, nitrogen-purged, three liter, four neck, round bottom flask was charged 272.7 g of polybutadiene latex (Polysar PL-662) (55% polybutadiene). The flask was fitted with a stirrer, thermometer, reflux condenser and 1000 ml addition funnel. A solution was prepared by mixing 12.0 g sodium stearate, 0.9 g sodium bicarbonate, 1.5 g sodium hydroxide, 3.0 g potassium persulfate and 1322 g deionized water. The mixture was heated to 60° C. while stirring until a clear, homogeneous solution was obtained. This solution was then charged into the reaction flask to dilute the stirred polybutadiene latex. A solution containing 435.6 g of the mixture of Example 1, 164.4 g acrylonitrile and 2.7 g tert-dodecyl mercaptan was prepared and placed in the addition funnel. With stirring and the charge temperature controlled at 60° C., monomer addition was started and maintained at 0.5%/min. After all the monomer had been added, polymerization was allowed to proceed for one additional hour. The latex was sampled to determine conversion by measuring total solids content. Antioxidant was added to the latex in the form of 42 g of an 18% emulsion containing 2/1--TNPP/Irganox 1076.

The ABPMS was recovered by pouring the hot, filtered latex into four volumes of rapidly stirred, 1.5% aqueous CaCl₂ solution at 100° C. The crumb was filtered and hot water washed. The crumb was vacuum-dried for 40 hours at 85° C. with a slow nitrogen sweep through the oven.

Conversion was over 95%. Precoagulum present in the latex was less than one percent, based on total resin. The yield of resin was about 740 g. Injection molded samples, prepared by direct mold of the dried resin crumb, had notched Izod Impact Strength of 6.3 ft. lb/in.

The product is suitable for extrusion or injection molding to form hard, tough, impact-resistance articles such as drain pipe or appliance housings.

EXAMPLE 7 Preparation of copolymers with styrene

A mixture of 6.00 g, the monomer mixture of Example 1, 18.00 g styrene monomer, 10.30 g of toluene, and 0.0336 g azoisobutyronitrile initiator (DuPont "Vazo 64") was heated in a nitrogen atmosphere (nitrogen bubbled through for 10 minutes) at 60° C. for 119 hours, and then at 90° C. for 24 hours. The polymer was removed from the tube with th aid of more toluene, and precipitated by pouring the toluene solution into an excess of methanol in a blender. The polymer was dried in a vacuum oven at 80°-110° and 30 inches vacuum.

The reaction was repeated with 12 g. each of the monomer mixture, 18 g of the mixture and 6 g. of styrene and also with 24 g of styrene and of the monomer mixture to produce a range of samples having varying comonomer ratios.

The samples were compression molded and tested for tensile modulus on a Rheoribron machine. The results were as follows:

    ______________________________________                                         Polymer No.    6A      6B      6C   6D    6E                                   ______________________________________                                         MEB monomer, wt %                                                                             0       25      50   75    100                                  Styrene, wt %  100     75      50   25     0                                   Modulus, psi × 10.sup.-3                                                                332     382     329  356   331                                  Pentane uptake, percent                                                                       1.0     1.5     23   30.5   41                                  ______________________________________                                          The copolymer with 75% styrene has a notably high tensile modulus.       

EXAMPLE 8 Preparation of a copolymer with acrylonitrile

A mixture of 22.50 g, the monomer mixture of Example 1, 2.50 g of acrylonitrile monomer, 10.90 g. of toluene (reagent grade) and 0.0350 g azoisobutyronitrile initiator (DuPont "Vazo 64") was heated in a nitrogen atmosphere (nitrogen bubbled through for 10 minutes) at 60° C. for 96 hours, then at 90° C. for 24 hours. The polymer was removed from the tube with the aid of more toluene, and precipitated by pouring the toluene solution into an excess of methanol in a blender. The polymer was dried in a vacuum oven at 80° C. first 20 hours, then at 110° C. and 30 inches vacuum for 50.0 hours. The glass transition temperature was 107° C.

A plaque was pressed from the polymer and a specimen put in pentane at 23° C. After 24 hours the specimen was removed from the pentane and weighed. From a plot of its weight vs. time, the pentane uptake was calculated at 4.18±0.09%, compared to 40 to 41% uptake of pentane by three homopolymers of the mixture prepared in the same fashion. The addition of acrylonitrile therefore reduces the affinity for hydrocarbons substantially. This is of great utility in foam extrusion, indicating that the copolymers of reduced hydrocarbon affinity are useful as foamable resins.

EXAMPLE 9 Cross-linking of the homopolymer by chemical cross-linking agent

A polymer of the monomer mixture of Example 1 was prepared in the manner described in Example 1.

The polymer was dissolved in toluene to give a 20% by weight concentration. Six samples were prepared and to four of them 1.5 wt percent (based on polymer) of dicumyl peroxide was added. Films about 5-8 mil thick were cast by pouring the solutions into aluminum dishes and allowing the toluene to evaporate. The films in the dishes were further dried in a vacuum oven at 50° C. for 45 minutes.

The films were placed in an oven at 205° C. for the indicated time in minutes:

    ______________________________________                                         Film No.             8A    8B    8C  8D  8E  8F                                ______________________________________                                         Film with peroxide (min.cure)                                                                       2     4     6   8   --  --                                Film without peroxide (min.cure)                                                                    --    --    --  --  0   6                                 ______________________________________                                    

The films were then placed in toluene. Films 8E and 8F dissolved in less than 5 minutes. Films 8A to 8D did not dissolve.

EXAMPLE 10 Preparation of a block copolymer with ethylene oxide

A quantity of 34.5 ml of the monomer mixture of Example 1 was dissolved in 2000 ml of hexane in a 3 1. flask equipped with a stirrer. To this was added 242 g of butadiene. After degassing and purification the monomer mixture was initiated with 1.5 ml of 2.3ON butyl lithium in the presence of 1.3 ml tetra hydrofuran which was used as a randomizing agent. The polymerization was allowed to proceed at 50° C. for 41/2 hr at which time the reaction was terminated with a small amount of ethylene oxide followed by an equally small amount of acetic acid. The polymer solution was then hydrogenated using a Ni/ Keiselguhr catalyst. After essentially complete hydrogenation of the butadiene double bonds, the catalyst was removed by filtration. The polymer solution containing 30 g of the hydrogenated polymer was then reacted with 0.342 ml of 1.095 N potassium t-amyloxide. A quantity of 8.35 ml of ethylene oxide was then added and the polymerization of the ethylene oxide was carried out at 90° C. for 16 hr.

The resulting block copolymer was then dissolved in oil at 1.2 wt %. It raised the viscosity of the oil from about 8 cS to 17 cS at 100° C.

EXAMPLE 11 Preparation of a copolymer with tertiary butylstyrene

A mixture of 10.0 g of the mixture of Example 1, 13.6 g of tertiary-butylstyrene monomer, 7.8 g of toluene and 0.0330 g of azoisobutyronitrile initiator (DuPont "Vazo 64") was freed of air by bubbling nitrogen gas for 10 minutes, and then it was heated successively at 60° C. for 96 hours, and 90° C. for 24 hours. The polymer was removed from the tube with additional toluene (110 ml), and precipitated by pouring into methanol (600 ml). It was dried at 80° C./30 inches vacuum for 23 hours, and at 100° C./30" vacuum for 22 hours. The number average molecular weight measured by osmometry was 228,000.

A solution of 2.15% by weight of the polymer in a lubricating oil had a viscosity index of about 147, and a pour point of -30° F. The estimated requirement for the oil was about 4% by weight. (Actual 2.15% solution viscosities were 53.54 cs at 40° C. and 8.93 cs at 100° C.).

The polymer may also be added directly to the oil from the toluene solution, and the toluene removed, or made in a purified oil of the desired type.

EXAMPLE 12

Sulfonation of the polymer

The polymer of Example 1 was dissolved in toluene and sulfonated at ambient temperature with chlorosulfonic acid in varying amounts. The sulfonation products were neutralized with sodium hydroxide or ammonia and the solvent removed.

The properties of the products were as follows:

    ______________________________________                                               Moles                                                                          Cl So.sub.3 H/      New-                                                       Mole                trali-                                               Expt. Monomer   Conditions                                                                               zation Properties                                    ______________________________________                                         11A   0.46      25°/30 min                                                                        NaOH   water soluble                                                                  Insol CHCl.sub.3                                                               Toluene, hexane                               11B   0.20      25°/2 hr                                                                          NH.sub.3                                                                              water insoluble                                                                methanol soluble                                                               toluene insoluble                             11C   0.10      25°/2 hr                                                                          NH.sub.3                                                                              Insoluble water                                                                hexane, swollen                                                                in toluene                                    ______________________________________                                    

The products of Experiments 11B and 11C could be pressed into high softening point films. The glass transition temperature of the product of Experiment 11B was 140° C. and that of Experiment 11C was 113° C.

EXAMPLE 13 Preparation of a brominated polymer

Bromine (13.5 g dissolved in 50 ml of methylene dichloride was added dropwise to a solution of 10 g of the polymer of Example 1 dissolved in 100 ml of methylene dichloride containing 0.2 g of FeBr₃ during 30 minutes with stirring in an ice bath. Stirring was continued for 30 minutes and the mixture was then allowed to warm to room temperature with stirring overnight. The resulting solution was washed with water, potassium carbonate solution and the polymer precipitated by addition to methanol.

After drying there was isolated a product with the analysis:

    ______________________________________                                         C              H            Br                                                 ______________________________________                                         56.52          4.89%        38.74%                                             ______________________________________                                    

The product was dissolved in toluene and treated with a solution of potassium - t - amyl oxide to remove small amounts of reactive bromine. The resulting product was thermally stable and could be pressed into films which were self extinguishing and did not support combustion.

EXAMPLE 14 Preparation of a chlorinated polymer

Chlorine was bubbled into a solution of 10.0 g of the polymer of Example 1 in 100 ml of methylene dichloride containing 0.2 g of FeCl₃ at room temperature over 4 hours. The resulting solution was washed with 10% K₂ CO₃ solution and water and the polymer isolated by precipitation in methanol.

Analysis of the polymer after drying showed:

    ______________________________________                                         %C             %H           %Cl                                                ______________________________________                                         75.57          6.59         17.89                                              ______________________________________                                    

To remove traces of reactive halogen, the polymer was dissolved in toluene and treated with potassium - t - amyloxide. The treated polymer could be molded into high softening temperature films.

EXAMPLE 15 Thermosetting blends with polyester resins

In this Example, the polyester resins shown in Table 1 below were used:

                  TABLE 1                                                          ______________________________________                                         POLYESTER RESINS EVALUATED                                                     PRO-                                                                           DUCER  DESIGNATION  POLYESTER TYPE                                             ______________________________________                                         Grace  GR 941 base resin                                                                           General purpose low                                                            viscosity, non promoted                                    Grace  GR 665 base resin                                                                           Flexible resin                                             Reichold                                                                              33-031       Rigid, low viscosity, low                                                      reactivity thixotropic promoter                            Koppers                                                                               1000-25      General purpose, low reactivity,                                               medium viscosity                                           Koppers                                                                               6000-25      Isophthalic resin, high reactivity                         ______________________________________                                          The polyester resins were formulated with styrene, vinyl toluene               (approximately 60% mmethylstyrene 40% pmethylstyrene VT) and the monomer       mixture of Example 1 (MEB). The mixtures were compatible in all cases.   

The viscosities of the mixes are as shown in Table 2 below:

                  TABLE 2                                                          ______________________________________                                         POLYESTER    MONOMER         Viscosity 30° C.                           Resin        Type      % Conc.   Cp. × Density                           ______________________________________                                         GR 665       Styrene   38.5      327                                           GR 665       MEB       38.7      420                                           GR 665       VT        37.8      453                                           GR 941       Styrene   40.0      243                                           GR 941       MEB       40.0      418                                           GR 941       VT        40.0      400                                           GR 511       Styrene   40.0      124                                           GR 511       MEB       40.0      149                                           GR 511       VT        40.0      154                                           Koppers 1000-25                                                                             Styrene   26.5      1450                                          Koppers 1000-25                                                                             Styrene   40.0      162                                           Koppers 1000-25                                                                             MEB       26.5      3390                                          Koppers 1000-25                                                                             MEB       40.0      215                                           Koppers 1000-25                                                                             VT        26.5      3640                                          Koppers 1000-25                                                                             VT        40.0      293                                           Koppers 6000-25                                                                             Styrene   31.2      2570                                          Koppers 6000-25                                                                             Styrene   40.0      485                                           Koppers 6000-25                                                                             PMS       31.2      3650                                          Koppers 6000-25                                                                             PMS       40.0      680                                           Koppers 6000-25                                                                             VT        31.2      4620                                          Koppers 6000-25                                                                             VT        40.0      745                                           Reichold 33-031                                                                             Styrene   40.0      145                                           Reichold 33-031                                                                             PMS       40.0      212                                           Reichold 33-031                                                                             VT        40.0      227                                           ______________________________________                                    

The results in Table 2 show that the mixes with the MEB according to the present invention generally have a lower viscosity (at the same concentration) than the mixes with vinyl toluene. This facilitates handling and use of the mixes.

Samples of two resin systems containing styrene, vinyl-toluene, and MEB were then cured as thin films under identical conditions and the modulus properties of these films measured as a function of temperature using the Rheovibron thermomethanical analyzer.

The resins were prepared and cured in the following manner:

Samples of resin containing 40% of styrene and equal weights and equal molar amounts (40% and 43%) of vinyltoluene and MEB. These samples were then treated with 4% Lupersol 224 (4% active oxygen) and 0.5% of a 3% solution of cobalt octoate and press cured as a thin film at 60° C. for 30 minutes followed by an oven post cure at 110° C. for an additional 30 minutes.

Samples were then cut from these films for Rheovibron analysis. Modulus temperature characteristics of these films were measured fro 25° C. to 130° C. and the glass transition temperature obtained from the maximum in the loss modulus cure. The modulus values at 25° C. and 100° C. and the observed glass transition temperature are listed in Table 3. Surprisingly, it can be seen that the values of glass transition and 100° C. modulus for the MEB mixes are similar to those obtained for styrene while the values obtained for vinyltoluene are considerably different with glass transition temperatures being lower in one resin and higher in the other.

                  TABLE 3                                                          ______________________________________                                         TABLE 3A - GR 665 Polyester                                                                  Modulus (dynes/cm.sup.2 × 10.sup.-9)                       Monomer %       25° C.                                                                            100° C.                                                                           Tg °C.                              ______________________________________                                         Styrene     40      27.5      2.6     81                                       Vinyltoluene                                                                               40      32.3      13.5    102                                      MEB         40      29.4      3.4     79                                       ______________________________________                                         TABLE 3B - GR 941 Polyester                                                    Styrene     40      25        16.7    120                                      Vinyltoluene                                                                               43      24        10.6    107                                      MEB         43      27.3      11.7    116                                      MEB         40      26.8      14.4    118                                      ______________________________________                                    

EXAMPLE 16 Preparation of copolymer with acrylonitrile by suspension polymerization

A solution comprising the following ingredients was preheated to 60° C. while stirring until clear:

    ______________________________________                                                        Wt. g                                                           ______________________________________                                         Sodium stearate  22.5                                                          Sodium bicarbonate                                                                              1.5                                                           Sodium hydroxide 1.1                                                           Potassium chloride                                                                              1.5                                                           Potassium persulfate                                                                            3.8                                                           Water            1455.0                                                        ______________________________________                                    

The solution was charged into a clean, dry, nitrogen purged, three-liter four-neck, round bottom flask held in a 60° C. constant temperature bath. The flask was then fitted with a stirrer, thermometer, reflux condenser and a 1000 ml addition funnel. A solution of 544.5 g of the isomer mixture of Example 1, 205.5 g acrylonitrile and 4.5 g tert-dodecyl mercaptan (equivalent to 45.7 mole percent acrylonitrile in the feed) was added at the rate of 0.5% per minute. After all the monomer had been added the polymerization was continued for one additional hour.

The resin was recovered by pouring the hot, filtered latex into four volumes of 1.5% aqueous CaCl₂ solution, stirred rapidly at 100° C. The resultant crumb was filtered, washed with hot water and dried in vacuum oven for 40 hours with slow nitrogen sweep through the oven.

Conversion: 99%

The properties of the copolymer (compared to those of a styrene/acrylonitrile copolymer produced in the same way using a feed containing 45.7 mole percent acrylonitrile) are shown below:

    ______________________________________                                                        MEB/AN  Styrene/AN                                                             resin   resin                                                   ______________________________________                                         Mole percent AN                                                                from % N          43        43                                                 by NMR            49        42                                                 Heat loss %      0.3       0.8                                                 (lg. sample 24 hrs.                                                            at 100° C. vacuum)                                                      M.sub.w /M.sub.n (by GPC)                                                                       2.5       2.3                                                 Melt Index g/10 min.                                                                            7.4       6.0                                                 T.sub.G (DSC) °C.                                                                        110       105                                                 TGA, °C. (5% wt. loss)                                                  in air           380       375                                                 in N.sub.2       410       410                                                 ______________________________________                                     

I claim:
 1. A high molecular weight copolymer produced by the copolymerization of a monomer selected from the group consisting of styrene, tertiary butyl styrene and acrylonitrile; and a mixture of isomers of methyl ethenyl benzene wherein said mixture of isomers are present in the following proportions by weight of the isomer.
 2. The copolymer of claim 1 in which said monomer is styrene, and said copolymer has a higher tensile modulus than styrene homopolymer.
 3. The copolymer of claim 1 in which said monomer is acrylonitrile, and said copolymer has reduced affinity for hydrocarbon compared to the corresponding polymer prepared from said mixture of isomers of methyl ethenyl benzene absent acrylonitrile monomer.
 4. The polymer of claim 1 in which the isomers are present in the mixture in the following proportions by weight:1-methyl-2-ethenyl benzene 0 to 0.05% 1-methyl-3-ethenyl benzene 1 to 5% 1-methyl-4-ethenyl benzene at least 95%.
 5. The polymer of claim 1 in which the isomers are present in the mixture in the following proportions by weight:1-methyl-2-ethenyl benzene 0 to 0.05% 1-methyl-3-ethenyl benzene 1 to 3% 1-methyl-4-ethenyl benzene at least 97%.
 6. The copolymer of claim 1 in which the comonomer is acrylonitrile.
 7. The copolymer of claim 1 in which the comonomer is styrene.
 8. The copolymer of claim 1 in which the comonomer is tertiary butyl styrene.
 9. The copolymer of claim 1 which is a random copolymer. 